Casting apparatus



Jan. 9, 1940. H. E.MWANE CASTING APPARATUS Original Filed Oct. 17, 1934 4 Sheets-Sheet 1 Jim. 9 1940. H E McWANE CASTING APPARATUS original Filed Oct. 17, 1954 4 Sheets- Sheet 2 Ema/14M Jan. 1940- B MCWANE 2 186 260 CASTING APPARATUS Original F'ile d Oct. 17. 1934 4 Sheets-Sheet 3 7/ z: 2; 3mm

Wen/M1116 Jan. 9, 1940. H. E.'M WANE CASTING AI PARATUS Original Filed om. 17, 1954 4 Sheet-Shet 4- Patented Jan. 9, 1940 UNITED STATES PATENT OFFICE Application October 17, 1934, Serial No. 748,730 Renewed August 9, 1938 9 Claims.

This invention relates to casting, and more particularly has reference to a ladle and mold construction.

Certain disadvantages have inhered in the former processes of casting, resulting largely from the construction and operation of the mold and ladle. In general, the devices of the prior art have been diflicult to operate and have necessitated an inordinate amount of manual labor.

In view of the fact that the quality of the cast- .ing was largely dependent upon the skill of the operator, losses due to defective castings have been appreciable in the past. Furthermore, there has been a large loss due to the solidification of molten metal in the gates and sprues. In the present practice with sand molds and metal molds, only about 70% of the molten metal is used in the casting, and approximately 30% is lost in the gate and sprue and has to be remelted.

*9 To overcome the above disadvantages is one of the objects of my invention.

Another object of my invention is to provide a mold and ladle construction which is largely automatic in operationand therefore independent of the skill of the operator.

Yet another object of my invention is to provide a casting apparatus relatively inexpensive to construct and affording marked economies in operation.

Still another object of my invention is to provide a casting operation in which losses of molten metal in the gate and sprue are maintained at a minimum. With these and other objects in view which may be incident to my improvements, the invention consists in the parts and combinations to be hereinafter set forth and claimed, with the understanding that the several necessary elements comprising my invention may be varied in construction, proportions and arrangement, without departing from the spirit and scope of the appended claims.

In order to make my invention more clearly understood, I have shown in the accompanying drawings means for carrying the same into practical effect without limiting the improvements in their useful applications to the particular constructions which, for the purpose of explanation, have been made the subject of illustration.

In thedrawings:

Figure 1 is a side elevation of an apparatus embodying my invention, looking at the ladle from the mold side.

Figure 2 is a top plan view of the device shown in Figure )1 Figure 3 is an end elevational view of the device. Figure 4 is a sectional view of the ladle and mold.

Figure 5 is a detail view of the dipping mechanism at the bottom of its revolution.

Figure 6 is a sectional view of the dipper and mold when the former is in the position shown in Figure 5.

Figure 7 is a view similar to Figure 5, but showing the dipper slightly above the horizontal.

Figure 8 is a view partly in section of the dipper and mold when the former is in the position of Figure '7.

Figure 9is a sectional view of the dipper at the top of its revolution.

Figure 10 is a sectional view of the dipper and mold when the dipper is at the top of its revolution.

Figure 11 is a view partly in section of the dipper on its downwardpassage.

Figure 12 is a view partly in section and partly in elevation of the 'dipper and mold when the dipper is in the position shown in Figure 11.

Figure 13 is a view in detail of the mold and operating means therefor, and particularly the fluid conduits for the various elements.

Figure 14 is a sectional view along the line ll-ll of Figure 13, looking in the direction of the arrows.

Figure 15 is a sectional view along the line I5-l5 of Figure 13, looking in the direction of the arrows.

Figure 16 is a sectional view of a modified form of dipper.

Figure 1'7 is a view of my invention as applied to a battery of molds operating on a single ladle, and in association with a cupola and forehearth construction.

Referring particularly to Figures 1 and 4, it will be observed that I provide a ladle l which may be composed of a casing, 2, insulating brick 3 and flre brick I. For reasons which will be hereinafter apparent, it is very desirable that ample insulation be provided to prevent the loss and passage of heat through to the casing. In order tofacilitate discharge of the ladle upon completion of the casting operations, I prefer that the bottom of the ladle be rounded, and that it slope slightly toward one end, the left end of Figure 1.

A cover, designated generally 5, is provided, which is preferably arched, as' shown in Figure 4. The cover may be hinged as at 6. The metal casing, insulating brick and fire brick are ema ployed for the cover as in the case of the body portion of the ladle.

An aperture I may be provided at one end and another aperture 8 at the opposite end and adjacent the base. The aperture 8 communicates with a trough member 3 which in turn has a. discharge outlet which is normally closed by a plug l2. Metal is introduced to the ladle by pouring the necessary amount into the trough 9, whence it passes through the aperture 8 to the interior of the ladle. It will be appreciated from what follows that a fairly accurate control of the liquid level in the ladle is desirable, and of course this can be readily regulated because the level within the ladle will be the same as that existing within the trough 9. However, to insure that the level shall not exceed the maximum, the aperture 1 serves as an overflow.

Rotatably mounted on one side wall of the ladle is a mold and a dipping member. To afford suflicient support, I provide an annular bearing member 13 which is suitably secured to one wall of the ladle by means of bolts l4, or other suitable fastening means. The bearing member I3 is provided with a suitable race l5 for roller bearings l6. Rotatably mounted on the roller bearings is a hub I! which also is provided with a suitable race member l8. The hub I1 is centrally drilled to receive a section of refractory material N which extends into the interior of the ladle l. The member I9 is provided with an annular flange 20 which is adapted to afford a fluid tight fit with the casing 2, insulating brick 3 and fire brick 4 of the ladle. As heretofore pointed out, the ladle is suitably insulated, and this is for the purpose of maintaining the temperature at the points of bearing at a minimum.

As best shown in Figure 2, the member 19 is bent to form an arm 2| which extends longitudinally of the ladle. The arm 2| terminates in a cup or dipper 22. Referring to Figure 7, for instance, it will be noted that the dipper 22 is made up of a cup portion 23 provided with an overhanging lip 24, for a purpose to be later described. It will be noted that the arm 2| and member I9 are formed with a channel 25. This channel places the cup portion 23 in communication with a mold to be described. There may be integrally formed with the hub l1 an arm 26 which afiords support for the refractory material of the dipper and arm 2|.

The hub I1 is also provided with a shelf portion 21 extending away from the ladle. The shelf portion 21 may be either integrally formed with the hub H or may be suitably secured thereto, and I preferably employ a strengthening web 28 to afford additional support. On the shelf 21 there is located a reservoir 29 which is adapted to receive a cooling medium and which is in heat exchange relationship with the lower half 3| of a mold. The mold 3| is removably secured in a suitable seat in the shelf, and may be replaced for different type castings or in the event of wear or repair. The section 3| is held in its seat by means of a set screw 32.

Extending upwardly from the shelf 21 is a supporting arm 33 which carries a cylinder 34. The cylinder 34 is provided with a piston 35 and piston rod 36. The piston rod carries the upper half 31 of the mold. The mold section 31 is provided with a liquid reservoir 38 for the purpose of appropriately cooling the mold; the section 31 may be replaced when desired, as in the case of. the lower section 3|. The reservoir 36 is provided with a grooved finger 39 which is adapted to travel along a flange 4| formed on supporting arm ,33. This serves to guide the mold section 31 and to prevent its rotation. The supporting arm 33 may be strengthened by the use of webs 42 and 43.

The mold supporting structure receives a shaft 44 which is axially aligned with the flange 28. The shaft 44 is journaled in a split bearing member 45, and is provided with a crank 46 and a handle therefor 41 a't'its free end and on the opposite side of the bearing. The bearing is supported by a suitable standard 48 which is properly mounted on the ground or support for the assembled device.

Referring particularly to Figure 13, it will be noted that the lower section 3|, and more particularly its cooling reservoir 29, is provided with an inlet pipe 49 which supplies the reservoir with a suitable cooling medium, such as water. The water passes out of the reservoir by way of a discharge pipe 5|. The upper mold section 31 is provided with a flexible inlet pipe 52 supplying the upper reservoir 38 with the cooling medium, such medium being exhausted from the reservoir by means of flexible conduit 53. It is of course necessary that the conduits 52 and 53 be flexible, in view of the fact that the upper half of the mold is adapted to be raised and lowered.

In order to actuate piston 35, a suitable fluid, such as air, is introduced and exhausted from the cylinder. As clearly shown in Figures 4 and 13, a pipe 54 is tapped into the upper part of the cylinder above the piston, and the pipe 55 is tapped into the lower part of the cylinder. Therefore, the introduction of air into the upper part of the cylinder through pipe 54 effects a closing of the mold sections, while an introduction of air beneath the piston raises the upper section of the mold. While I have referred to air as the actuating medium, it will of course be appreciated that tne piston may be hydraulically operated, if desired.

As indicated above, the dipper 22 and the mold and supporting structure are rotatable. In view of this, I have shown inFigures 13 through 15 the means for supplying the reservoirs and the cylinder with their respective fluids. It will be noted that the shaft 44 is provided with a plurality of longitudinally extending channels 56, 51, 58, 59, 6| and 62. From these longitudinal channels there extend radially to the periphery of shaft 44 channels 63, 64, 65, 66, 61 and 68, respectively.

Referring particularly to Figure 15, it will be noted that pipe 49 is suitably fitted in radial channel 63, pipe 5| is suitably secured in radial channel 64, pipe 54 in channel 55, flexible conduit 53 in channel 66, flexible conduit 52 in channel 61-, and pipe 55 in channel 68.

The bearing 45 is provided with a series of interior annular channels 69, 1|, 12, 13, 14 and 15. Suitable gaskets 16 are provided intermediate each of these channels and on the outside of each of the channels 69 and 15. As best shown in Figure 14, the longitudinally extending channels 56, 51, 58, 59, 6| and 62 communicate with radially extending channels 11, 18, 19, 8|, 82 and 83, respectively. The radial channel 1! is adapted to register with annular channel 15. radial channel 18 with annular channel 14, channel 19 with channel 69, channel 8| with channel 12, channel 82 with channel 13, and channel 83 with channel 14. It will, therefore, be seen that the various pipes 49 through 54 are constantly in communication with the respective channels through I5, regardless of the rotation of the mold and associated structure.

There are suitable conduits tapped into the several channels 89 through I5. For instance, a pipe 84 communicates withchannel 18 to supply the cooling medium to the lower half of the mold. A pipe 85 is tapped into channel 14 to receive the water exhausted from the cooling jacket of the lower mold section 3|. Pipe 88 supplies channel I3 and consequently the cooling jacket in the upper part of the mold, with the cooling medium, while the exhausted cooling medium passes out of channel I2 into pipe 81. Pipe 88 is tapped into channel II which communicates with the lower end of the cylinder 34. Pipe 89 is tapped into channel 69 and supplies the upper portion of the cylinder with air.

It will be appreciated, of course, that the gaskets I8 maintain the several channels 89 through I in an air tight fit with the shaft 44 and prevent the leakage of air or water from one channel into another.

I provide a valve 9I to control the air admitted and exhausted from the cylinder 34. This valve is made up of a valve casing 92 and a valve block 93 rotatable therein. Valve block 93 is provided with a channel 94 which is flared at one end as at 95. The casing is provided with apertures, threaded at their outer ends, numbered 98, 91 and 98, and into these are tapped pipes 89 and 88 and an air inlet pipe 99, respectively. It will be noted that the channel 94, with its flared end 95, is adapted to place either pipe 89 or 88 in communication with air inlet pipe 99. When pipe 89 is in communication with the inlet pipe, pipe 88 through aperture 91 is in communication with a radial channel I9I which opens into the atmosphere through aperture I92. When pipe 88 is in communication with the air inlet pipe, channel 98 registers with a radial channel I93 which is open to the atmosphere through aperture I94. Consequently, when air is admitted to either of pipes 88 or 89, the other pipe is in communication with the atmosphere to permit of the exhaust of the air from the other side of the piston.

As an example, Figure 13 shows pipe 89 in com-.

munication with air inlet pipe 99, which means that air is being admitted to the top of the cylinder and above the piston. At the same time, the lower part of the cylinder is being exhausted inasmuch as pipe 88 is in communication with the atmosphere. Consequently, the upper mold section 31 is lowered to close the mold. In order to raise or open the mold, the valve handle I95 is turned to rotate the valve block 93 so that the channel 94 registers with aperture 91. This introduces air into the lower part of the cylinder and exhausts the air above the piston through pipe 89, aperture 98, channel I93, and port I94.

Figure 1'7 shows an arrangement of a battery of molds operating from a single ladle I98. The ladle I98 is obviously elongated from the ladle shown in the other figures in the drawings, but in all other respects may be of similar construction. Also, each of the molds I91, I98, I99 and III, together with their associated mechanism, is similar to the structure described above.

Also, in Figure 1'? I have shown the use of a cupola H2 and forehearth H3 in communication therewith. The cupola and forehearth may be of the construction described in my copending application Ser. No. 707,959, filed January 23, 1934 or of some other suitable form. A spout II4 discharges molten metal from the forehearth into trough 9. I prefer the use of a cupola and forehearth inasmuch as they permit of a closer control of the level of molten metal in the ladle and of course such an arrangement may be employed whether there is a single mold or a plurality of molds operating from the same ladle.

In Figure 16 there is shown a modified form of dipper which may be preferable under some circumstances. This dipper is generally similar to the dipper shown in the other figures of the drawings, but the channel 25 instead of communicating with the cup 23 at the upward part of the cup, extends from the base of the cup by way of a horizontal channel 25a and an upwardly inclined channel 25b. As will be apparent from a description of the operation of my device, this modified form of dipper further insures the discharge of metal from the cup and channel 25 upon inversion of the dipper.

The operation of my device is believed to be obvious from the foregoing. Molten metal is charged into trough 9 either directly from a eupola or by way of a forehearth such as shown in Figure 1'7. A sumcient amount is supplied to the trough 9 until the desired liquid level is attained in the ladle. Usually this is approximately as indicated in Figure 4, but of course it can be varied as desired. Normally, the overflow outlet I governs the maximum level, but if it is desired to exceed this, a clay body may be inserted in aperture 1. When the proper level is reached and it is desired to commence the casting operation, crank 48 is turned to rotate the mold, dipper, and associated elements. The dipper is usually started from a position such as shown in Figure 11, and consequently the cup is inverted at such time.

Upon the cups entering the body of molten metal in the ladle, the metal fllls the cup. Continued rotation raises the cup together with the major part of its contents above the metal in the ladle. When the cup reaches approximately the level of the horizontal axis of rotation, the metal contained in the cup flows through channel 25 and into the mold cavity. When the cup is slightly above the horizontal, the metal will be distributed substantially as shown in Figures '7 "and 8, that is, with a portion of the mold cavity filled. For a reason to be later adverted to, the mold and its cavity slants upwardly from its point of junction with member I9, and consequently in the position indicated in Figures 7 and 8, the mold is not entirely filled.

Further rotation, however, does completely fill the mold, as shown in Figures 9 and 10. It will be noted that this is assured by virtue of the fact that the head of metal in channel 25 is above the top of mold cavity I I5. It is to be noted that suitable vents I I8 are drilled into the mold cavity.

It will be appreciated that with still further rotation of the mold and dipper, the cavity remains filled, fora limited part of such further rotation. At a certain point in the cycle, how ever, the metal in channel 25 will begin to recede toward cup 29, but there will be an appreciable recession before there is any tendency toward the fiow of metal from the mold. The lip 24 of the form of dipper shown in Figures 5 through 12 and the channels 25b and 25a of the form of dipper shown in Figure 16 tend to retard the actual egress of metal from the cup 23 back into the molten, mass in the ladle.

The significant feature of my invention is the fact that prior to such egress of metal from the cup 23 and prior to what would normally be a fiow of metal out of the mold cavity, the casting in such cavity has sufliciently hardened so that there is no liquid there present. At the same time, the channel 25 and dipper 22 are so eihciently insulated that the metal therein remains in a molten condition and thereby runs back into the molten mass in the ladle. In this connection it is to be particularly noted that the mold slants upwardly to a limited extent when the various elements are in the postition shown in Figures 7 and 8. Further rotation, however, reverses such positions; and when the elements reach the positions shown in Figures 11 and 12 (at which time the molten metal flows from the cup 23) it will be noted that the mold slants downwardly. This slanting of the mold has two important aspects. In the first place, it insures that the metal entering the mold will flow upwardly and thereby result in a better casting, and of equal importance is the fact that at the time the metal begins to recede from channel 25, the mold slopes downwardly as in Figure 12, thus further preventing any flow of metal from the mold cavity quite aside from the fact that the metal in the cavity has solidified.

It will of course be obvious that there are certain conditions to be met in the construction and operation of my device, but it is believed that a person skilled in the art will appreciate such conditions for any given operation. For instance,

, the length of arm 2|, the size of the cup 23, channel 25 and mold cavity H must be correlated so that when the dipper is in the position-shown in the Fig. 10, the head of metal in channel 25 will be suflicient to completely fill the mold. Also, it

will of course be obvious that the speed of rotation of the mold and dipper should be such that the metal in the mold cavity will solidify'before there is any tendency for such metal to recede from the cavity.

The opening and closing of the mold has already been described, and it will be appreciated that a slight manipulation of the valve lever I05 eifects such opening and closing. Of course it is obvious that by properly regulating the amount of water introduced to pipes 84 and 86, the desired cooling of the mold and casting may be secured.

I prefer that the device be operated by completely rotating the mold and dipper, but it is of course obvious that they may be partially rotated to a position such as that shown in Figure 10, whereby the mold cavity is completely filled and then the direction of rotation reversed to permit the molten metal to flow out of the channel 25 and cup 23.

It is believed that the advantages of my invention are readily apparent. It is comparatively simple and of inexpensive construction, and there is a minimum of wear and need for replacements. It is largely automatic in operation and therefore does not depend upon the skill of the operator save only with respect to the speed of operation. In this connection, the shaft 44 could be readily driven by power to insure the desired speed. It

will also be noted that there is a minimum of loss resulting from gates and sprues inasmuch as practically all the metal save that in the mold cavity is returned to the molten mass. It has also been found that castings of superior quality are secured by my apparatus.

While I have shown and described the preferred embodiment of my invention, I wish it to be understood that I do not confine myself to the precise details of construction herein set forth by the spirit of the invention, or exceeding the scope of the appended claims.

I claim: 1. A casting apparatus comprising a ladle, a

mold secured to the ladle, and dipping means in communication with the mold, said mold and dipping means adapted to be rotated so that the dipping means will be raised to a point above the mold to thereby permit the molten metal in the dipping means to flow into the mold.

2. A casting apparatus comprising a ladle, a mold secured to the ladle, and dipping means in communications with the mold, said mold and dipping means adapted to be rotated to a point above the mold so that any molten metal in the dipper will flow into the mold, said communicating means adapted to enter the base of the mold cavity.

3. A casting apparatus comprising a ladle, a mold, a dipper, and a'channel member connecting the mold and the dipper, said dipper and channel member being rotatably mounted about a horizontal axis on the ladle, and being of suflicient length and size that when the dipper is in raised position, the head of metal in the channel member will be above the top of the mold cavity.

4. A casting apparatus comprising a ladle, a mold, a dipper and a channel member connecting the mold and the dipper, said mold, dipper and channel member being mounted on the ladle for rotation, and said dipper and channel member being of such length and size that at substantially all times when the dipper is above the horizontal axis of rotation the head of metal in the channel member will be higher than the top of the mold cavity.

5. A casting apparatus comprising a ladle, a mold secured to the ladle, and dipping means in communication with the mold, said mold and dipper being rotatable so that the dipper may be raised to a point above the mold to permit the flow of molten metal from the dipper into the mold cavity, said mold being sectional and provided with fluid actuated means for opening and closing such sections.

6. A casting apparatus comprising a ladle, a mold, a dipper and a channel member connecting the mold and the dipper, said mold, dipper and channel member being mounted on the ladle for rotation about a horizontal axis, and said dipper and channel member being of such length and size that at substantially all times when the dipper is above the horizontal axis of rotation, the head of metal in the channel member will be higher than the top of the mold cavity.

'7. A casting apparatus comprising a ladle, a mold, secured to the ladle, and dipping means in communication with the mold, said mold and dipper being rotatable about a horizontal axis so that the dipper may be raised to a point above the mold to permit the flow of molten metal from the dipper into the mold cavity, said mold being sectional and provided with fluid actuated means for opening and closing said sections.

8. In a casting apparatus, a source of molten material, a movable channeled ladle arm, a dipper carried by the movable channeled ladle arm and in communication with the channel therein, said dipper being adapted to dip the molten material by oscillation of the channeled ladle arm, and a mold secured to the ladle arm and in constant communication with the channel in the ladle arm.

9. In a. casting apparatus, a source of molten material, a movable channeled ladle arm, a dipper carried by the movable channeled ladle arm and in communication with the channel therein, said dipper being adapted to dip the molten material by oscillation of the channeled ladle arm, a mold secured to the ladle arm and in constant communication with the channel in the ladle arm, and means to simultaneously swing the combination of dipper, ladle arm and mold.

HENRY E. MOWAN E. 

